Reinforced structural body

ABSTRACT

The present invention describes a hollow structural body such as an automotive unibody or frame rail that is reinforced with a reinforcing material such as a polyurethane foam by inserting into a portion of the structural body a bulkhead-containing insert, which, in combination with the structural body at the place of insertion, creates a containment region for the reinforcing material. Uncured reinforcing material can then be added to the containment region and cured.  
     The present invention solves a problem in the art by providing structural reinforcement to be easily and precisely placed within the structural body to provide, for example, enhanced crash resistance or improvements in acoustical properties.

CROSS-REFERENCE STATEMENT

[0001] This application claims the benefit of U.S. ProvisionalApplication No. 60/351,088, filed Jan. 22, 2002.

FIELD OF THE INVENTION

[0002] The invention relates to a structural body containing astructural reinforcing material. In particular the invention relates toreinforced structural, sealing, and acoustical vehicular bodies such asreinforced frame rails and unibodies.

BACKGROUND OF THE INVENTION

[0003] A hollow member (structural body) of a vehicle is often filledwith foam to seal, dampen noise, and to impart structural strength andrigidity or acoustical properties. Typically, a structural body isfilled with a foam such as polyurethane by introducing fluid reactantsinto a region that it is desired to reinforce (that is, a reinforcingregion) and allowing the foam to react and fill the reinforcing region.Unfortunately, this method is uncontrolled and the foam inconsistentlyfills the cavity from one vehicle to the next. The method, in manyinstances, also requires the use of specialized plugs to keep the foamfrom escaping and clogging up functional holes such as mounting holesfor other components.

[0004] U.S. Pat. Nos. 5,194,199, 5,866,052 and 6,062,624 disclose yetanother way of reinforcing structural bodies by inserting a pre-formedcured structural foam part into the structural body However, thisapproach relies on the use of an expandable polyurethane or epoxy resinto adhere the structural part into place, which resin detracts from theoverall structural performance of the part. Furthermore, the integrityof the structural part-structural body bond can be compromised due tothe inconsistency of the bake ovens used to cure the adhesive.Accordingly, it would be desirable to provide a structural reinforcementto be precisely placed within a structural body that is not subject tothe deficiencies of a sealant or that relies upon consistencies of bakeoven temperatures.

SUMMARY OF THE INVENTION

[0005] The present invention solves a problem in the art by providing amethod for reinforcing a structural body having a cavity comprising thesteps of a) inserting into a portion of the cavity of the structuralbody a bulkhead-containing insert which, in combination with thestructural body at the place of insertion, forms a containment regionfor a reinforcing material, which containment region has an inlet; b)sealing the insert to the structural body; c) adding through the inletof the reinforcing region a sufficient quantity of an uncuredreinforcing material to at least partially fill the containment region;and d) curing the reinforcing material.

[0006] In a second aspect the present invention is a reinforcedstructural body comprising a) a structural body having a cavity b) abulkhead-containing insert disposed and sealed within the cavity, whichinsert, in combination with the structural body at the place ofinsertion, defines a reinforcing region that is at least partiallyfilled with an uncured reinforcing material.

[0007] In a third aspect the present invention is a reinforcedstructural body comprising a) a structural body having a cavity b) abulkhead-containing insert disposed and sealed within the cavity, whichinsert, in combination with the structural body at the place ofinsertion, defines a reinforcing region that is at least partiallyfilled with a cured reinforcing material.

[0008] The present invention is particularly useful in reinforcing astructural body, particularly of a vehicular frame rail or unibody. Forexample, it is quite common for frame rails of automobiles to havesections that are weakened to create crush zones to dissipate the energyof an accident and protect the occupants. The frame rails also supportparts of the automobile such as the transmission. The present inventionprovides a way for a reinforcing material to be introduced selectivelyinto a portion of the frame rail without compromising the crush zone orclogging the mounting holes for other components such as engines andtransmission. The present invention may also be used to reinforce othercomponents of a vehicle such as rocker panels, beams, pillars,crossbars, body mounts and the like. Furthermore, the present inventionmay be used for non-vehicular applications such as athletic equipment(for example, golf clubs), boats, bicycles, aircraft, trucks and trains.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009]FIG. 1 is a perspective view of an automotive unibody fitted witha reinforcing part.

[0010]FIG. 2 is an enlarged cutaway view of the reinforcing partdepicted in FIG. 1.

DETAILED DESCRIPTION OF THE INVENTION

[0011]FIG. 1 illustrates an example of a preferred embodiment of thepresent invention. Structural body 100 is in the form of an automotiveunibody for illustrative purposes. Inserted and positioned within aportion of the cavity of the unibody 100 using, for example, mountingtabs, clips, screws, rivets, alignment pins, welds, or glue, is abulkhead-containing insert 110 that is placed in the region to bereinforced. The insert 110, in combination with a portion of the innerwall of the structural body at the place of insertion 10 a, confinessubsequently injected reinforcing material to the region defined by theinsert and the portion of the structural body at the place of insertion.Thus, the insert 110, by itself, is not a container, but rather forms areinforcing region for subsequently introduced reinforcing material incombination with the structural body by virtue of the presence of a) atleast one bulkhead 110 a associated with the insert and b) the innerwall of the structural body 10 a within the confines of the at least onebulkhead 110 a. (An insert with a single bulkhead may be appropriatewhere the place of insertion includes a pre-existing bulkhead.)

[0012] The reinforcing region is at least partially filled, morepreferably substantially completely filled, with a reinforcing material120, which is preferably a 2-part expandable foam such as an expandablepolyurethane or an expandable epoxy resin.

[0013] Turning now to FIG. 2, which is an enlarged cutaway view of theinsert 110 within a portion of the unibody 100, the insert 110 isadvantageously sealed to the unibody with a sealant 130. Also depictedis a protuberance 140 extending in the direction of the reinforcingmaterial 120. The protuberance 140, which can be made by any suitablemethod such as surface deforming or capping a hole, protects an opening150, typically a mounting hole or access hole, from being clogged withreinforcing material 120.

[0014] The structural body 100 can be made using any suitable material,the selection of which is application dependent. For example, for aframe rail or other tubular structural member of an automobile, thestructural body is advantageously formed of metal such as steel oraluminum or alloys thereof. Other suitable materials may be plastics,wood, ceramics, composites, glass and other materials rigid enough toform the structural body.

[0015] The insert 110 may be fabricated using any suitable material suchas those used to make the structural body 100, although the insert 110and structural body 100 need not be made with the same materials. Forexample, if the structural body 100 is a steel unibody, the insert 110is preferably a plastic or filler reinforced plastic that can withstandthe temperatures and stresses associated with manufacturing anautomobile. Examples of suitable plastics for such an applicationinclude nylon, polycarbonates, polystyrenes, polyolefins such aspolyethylene and poly propylene, a thermosetting resin such asphenol-formaldehyde, phenol furfural, polyurethanes, and epoxy resins.Preferably the plastic is a filler reinforced thermoplastic materialsuch as a glass reinforced nylon, commercially available as VYDYNE®reinforced nylon, (a trademark of The Dow Chemical Company). Preferablythe glass reinforced nylon has a volume to volume glass content of from10% to 40%.

[0016] The sealant 130 is preferably a low density heat expandable epoxysealer such as BETABRACE® epoxy resin (a trademark of The Dow ChemicalCompany). However, sealing can also be accomplished by using anon-expanding sealer. Moreover, sealing can also be accomplishedmechanically, for example, by using an elastomeric insert that conformsclosely to the contours of the unibody at the place of installation.

[0017] The reinforcing material 120 may be any material that enhancesstructural or acoustical properties of the structural body 100. Examplesof preferred materials include foams such as expanded polyurethane andexpanded epoxy resin. Preferably, the reinforcing material 120 is apolyurethane foam formed by a suitable method such as those known in theart. For example, the polyurethane foam may be made by any of themethods described in U.S. Pat. Nos. 4,390,645; 2,866,744; 3,755,212;3,849,146; 3,821,130 and 5,968,995, which descriptions are incorporatedherein by reference.

[0018] A preferred method of preparing a reinforced structural bodyincludes the steps of inserting into a portion of the cavity of thestructural body and affixing thereto a bulkhead-containing insert which,in combination with the structural body at the place of insertion,creates a reinforcing region. For the purposes of this invention, areinforcing region is a cavity that defines the region that it isdesired to reinforce.

[0019] The affixed insert is then heat sealed to the structural body toconfine the reinforcing material within the reinforcing region. Thereinforcing material, preferably an uncured 2-part polyurethane resin,is then added to the reinforcing region through an inlet, which caneither be pre-existing or created, to at least partially fill, morepreferably to substantially completely fill the reinforcing region. Thereinforcing material is then cured, preferably chemically or by heating,more preferably chemically.

[0020] The insert may be prepared by a variety of techniques includinginjection molding, blow molding, and stamping, with injection moldingbeing preferred. The insert is preferably injection molded into opposingand connectable halves that are snapped together and then affixed intothe structural body.

[0021] The following example is for illustrative purposes only and isnot intended to limit the scope of the invention.

EXAMPLES Example 1

[0022] A VYDYNE 30% volume-to-volume glass filled nylon 66 insert isinserted and held mechanically into a first frame rail half with a clipusing a locating hole in the first frame rail half. The insert, which iscoated with a 2-mm coating BETABRACE 85076 expandable epoxy foamadhesive, is designed to maximize the amount of foam that contacts theframe rail directly.

[0023] A second frame rail half is then welded to the first frame railhalf. The welded frame rail is then e-coated and the e-coat liquids flowfreely through all the cavities within frame rail. The welded frame railis then baked to a temperature sufficient to cure the e-coating and toseal the insert together with the frame rail by way of the concomitantlycured resin.

[0024] BETAFOAM 88100 isocyanate and BETAFOAM 88124 resin are injectedinto the inner cavity and allowed to cure forming a frame rail havingreinforcing solely within the confines of the insert and the portion ofthe frame to which it is inserted.

What is claimed is:
 1. A method for reinforcing a structural body having a cavity comprising the steps of a) inserting into a portion of the cavity of the structural body a bulkhead-containing insert which, in combination with the structural body at the place of insertion, forms a containment region for a reinforcing material, which containment region has an inlet; b) sealing the insert to the structural body; c) adding through the inlet of the reinforcing region-a sufficient quantity of an uncured reinforcing material to at least partially fill the containment region; and d) curing the reinforcing material.
 2. The method of claim 1 wherein the structural body is an automotive frame rail or unibody.
 3. The method of claim 2 wherein the uncured reinforcing material is an expandable 2-part polyurethane resin or an expandable 2-part epoxy resin.
 4. The method of claim 3 wherein the uncured reinforcing material is an expandable 2-part polyurethane resin.
 5. The method of claim 1 wherein the insert is heat sealed to the structural body by way of a heat activated expandable epoxy adhesive or a heat activated non-expandable silicone or acrylic adhesive or by mechanical means.
 6. The method of claim 1 wherein the insert is heat sealed to the structural body by way of a heat activated expandable epoxy adhesive.
 7. The method of claim 4 wherein the reinforcing material substantially fills the containment region.
 8. A reinforced structural body comprising a) a structural body having a cavity b) a bulkhead-containing insert disposed and sealed within the cavity, which insert, in combination with the structural body at the place of insertion, defines a reinforcing region that is at least partially filled with an uncured reinforcing material.
 9. The reinforced structural body of claim 8 wherein the structural body is an automotive frame rail or unibody.
 10. The reinforced structural body of claim 8 wherein the reinforcing material is an expandable 2-part polyurethane or an expandable 2-part epoxy resin.
 11. The reinforced structural body of claim 8 wherein the reinforcing material is an expandable 2-part polyurethane.
 12. The reinforced structural body of claim 11 which is sealed by way of an expanded epoxy adhesive or a silicone or acrylic adhesive or by mechanical means.
 13. The reinforced structural body of claim 11 which is sealed by way of an expanded epoxy adhesive.
 14. The reinforced structural body of claim 13 wherein the reinforcing material substantially fills the reinforcing region.
 15. The reinforced structural body of claim 14 wherein the insert is a filler reinforced thermoplastic.
 16. The reinforced structural body of claim 14 wherein the insert is a glass reinforced nylon.
 17. The reinforced structural body of claim 8 wherein the insert includes a protuberance projecting in the direction of the uncured reinforcing material.
 18. A reinforced structural body comprising a) a structural body having a cavity b) a bulkhead-containing insert disposed and sealed within the cavity, which insert, in combination with the structural body at the place of insertion, defines a reinforcing region that is at least partially filled with a cured reinforcing material.
 19. The reinforced structural body of claim 18 wherein the structural body is an automotive frame rail or unibody.
 20. The reinforced structural body of claim 18 wherein the reinforcing material is an expanded 2-part polyurethane. 